Variable Valve Timing Actuator: Service and Repair

VARIABLE VALVE TIMING ACTUATOR REMOVAL/INSTALLATION [L5]

NOTE:
- Variable valve timing actuator can not be disassembled because it is a precision unit.
- Intake camshaft sprocket is integrated with the variable valve timing actuator and cannot be disassembled.

1. Disconnect the negative battery cable.

2. Remove the plug hole plate. Service and Repair

3. Disconnect the wiring harness.

4. Remove the ignition coils. Service and Repair

5. Remove the spark plugs. Service and Repair

6. Disconnect the ventilation hose from the cylinder head cover.

7. Remove the dipstick.

8. Remove the cylinder head cover. Service and Repair

9. Remove the front wheel and tire (RH). Service and Repair

10. Remove the under cover.

11. Set the front mudguard (RH) out of the way.

12. Remove the splash shield (RH).

13. Remove the drive belt. Service and Repair

14. Remove the engine front cover lower blind plug.






15. Remove the engine front cover upper blind plug.






16. Remove the cylinder block lower blind plug, and install the SST.






17. Rotate the crankshaft in the direction of the engine rotation so that the No.1 piston is at top dead center (TDC) of the compression stroke. (Until the counterweight contacts SST and stops.)

18. Loosen the timing chain using the following procedure.
a. Insert a suitable bolt (M6 X 1.0, length 25-35 mm {1.0-1.3 in}) into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)






b. Using the cast hexagon on the exhaust camshaft, apply force counterclockwise to facilitate unlocking the chain tensioner ratchet.






c. Using a Hex bit socket (2.5 mm {0.098 in}) or T15 Torx bit socket, unlock the chain tensioner ratchet so that it can be lifted up.






d. Using the cast hexagon on the exhaust camshaft, apply force in the direction of the engine rotation to increase tension on the chain.






NOTE:
- The chain tensioner rack is compressed using the chain tension generated by applying force to the exhaust camshaft in the direction of the engine rotation.






e. Screw in the bolt set in Step 1 approx. 5 mm {0.2 in} and secure the tensioner arm with the rack compressed.
NOTE:
- The racket has not been unlocked if the bolt cannot be pressed in approx. 5 mm {0.2 in}.






- If the tensioner arm cannot be secured, return the bolt to its original position and repeat the procedure from Step 3.

19. Fix the exhaust camshaft using a wrench on the cast hexagon, and loosen the camshaft sprocket bolt.






20. Remove the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and washer as a single unit.

CAUTION:
- Perform the work carefully so that the washer does not drop out.






21. Remove the OCV. Service and Repair

22. Loosen the camshaft cap bolts in two or three steps in the order shown in the figure and remove the camshaft cap.
NOTE:
- The camshaft caps are to be kept ordered for correct reassembly in their original positions. Do not mix the caps.






23. Remove the variable valve timing actuator and the camshaft on the intake air side as a single unit.

24. Remove the variable valve timing actuator.
a. Mark the camshaft and variable valve timing actuator as shown in the figure to make sure they are installed in their original position.






b. Secure the camshaft in a vise.






c. Loosen the variable valve timing actuator tightening bolt.

25. Install a new washer.






26. Install the variable valve timing actuator.
NOTE:
- When the variable valve timing actuator is replaced with a new one, mark it in the same location as the old one.

a. Secure the camshaft in a vise.

b. Align the marks of the camshaft and variable valve timing actuator.

c. Tighten variable valve timing actuator tightening bolt.

Tightening torque
- 69-75 Nm {7.1-7.6 kgf-m, 51-55 ft-lbf}

NOTE:
- If the alignment marks on the variable valve timing actuator are not available, perform the sprocket position alignment again.

27. Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST.)

28. Apply the gear oil (SAE No.90 or equivalent) to each journal of the cylinder head as shown in the figure.






29. With No.1 cylinder cam aligned at TDC of the compression stroke, install the variable valve timing actuator and the camshaft on the intake air side as a single unit.

30. Apply the gear oil (SAE No.90 or equivalent) to each journal of the camshaft as shown in the figure.






31. Temporarily tighten the camshaft cap bolts evenly in 2-3 steps.

32. Tighten the camshaft cap bolts in the order shown in the following two steps.






Tightening procedure
- Step 1: 5.0-9.0 Nm {51-91 kgf-cm, 45-79 in-lbf}
- Step 2: 14-17 Nm {1.5-1.7 kgf-m, 11-12 ft-lbf

33. Install the OCV. Service and Repair

34. Install the exhaust camshaft sprocket bolt, exhaust camshaft sprocket, and a new washer as a single unit.

CAUTION:
- Install a washer to the fourth or fifth thread of the exhaust camshaft sprocket bolt being careful not to drop the washer.
- Do not tighten the camshaft sprocket bolt at this stage. Verify the valve timing before performing the bolt tightening.






35. Install the SST on the camshaft as shown in the figure.






36. Remove the bolt (M6 X 1.0 length 25-35mm {1.0-1.3 in}) from the engine front cover upper blind plug hole, and apply tension to the timing chain.

37. Fix the exhaust camshaft using a wrench on the cast hexagon, and tighten the sprocket bolt.






Tightening torque
- 69-75 Nm {7.1-7.6 kgf-m, 51-55 ft-lbf}

38. Remove the SST from the camshaft.

39. Remove the SST installed in the cylinder block lower blind plug hole.

40. Rotate the crankshaft clockwise two turns and inspect the valve timing.

- If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 35.

41. Install the cylinder block lower blind plug.






Tightening torque
- 18-22 Nm {1.9-2.2 kgf-m, 14-16 ft-lbf}

42. Apply the silicone sealant and install the engine front cover upper blind plug.






CAUTION:
- Install the engine front cover upper blind plug before the applied silicone sealant starts to harden.

Tightening torque
- 8-11 Nm {82-117 kgf-cm, 71-101 in-lbf}

43. Install a new engine front cover lower blind plug.






Tightening torque
- 10-14 Nm {102-142 kgf-cm, 89-123 in-lbf}

44. Install the drive belt. Service and Repair

45. Install the splash shield (RH).

46. Install the front mudguard (RH).

47. Install the under cover.

48. Install the front wheel and tire (RH). Service and Repair

49. Install the cylinder head cover. Service and Repair

50. Install the dipstick.

51. Connect the ventilation hose.

52. Install the spark plugs. Service and Repair

53. Install the ignition coils. Service and Repair

54. Connect the wiring harness.

55. Install the plug hole plate. Service and Repair

56. Connect the negative battery cable.